Process for producing glove having interpenetrating network structure

ABSTRACT

A process for producing an elastomeric article having an interpenetrating network structure included the following steps. Firstly, a mold is contacted with an elastomeric composition. The elastomeric composition includes a base latex and a thermoplastic ethylene-vinylacetate (EVA) copolymer latex. The base latex includes a styrene-butadiene rubber (SBR) latex and a carboxylated styrene-butadiene rubber (C-SBR) latex, and the mixing ratio of the base latex to the EVA copolymer latex is from 95:5 to 40:60. Then, the elastomeric composition on the mold is allowed to perform a vulcanization reaction, thereby forming the elastomeric article having the interpenetrating network structure.

CROSS REFERENCE TO RELATEDPATENT APPLICATION

This application is a divisional application of application Ser. No.10/447,723, filed May 29, 2003, which application is incorporated hereinby reference.

FIELD OF THE INVENTION

The present invention relates to a process for producing a glove, andmore particularly to a process for producing a glove having aninterpenetrating network structure.

BACKGROUND OF THE INVENTION

A conventional glove is produced by blending PVC materials withplasticizers. When such glove is combusted, for example in the case offire or being incinerated, the PVCs will be oxidized to generatecorrosive gases and toxic gases such as dioxin, and the plasticizerswill be oxidized to generate various contaminating substances. Thecorrosive gases are considered responsible for pulmonary edema whenbeing inhaled and for serious damages of instruments in contacttherewith. Dioxin and some of the contaminating substances might alsocause the problems of environmental hormone and the like. In views ofenvironmental protection, these conventional gloves have been eliminatedthrough competition. Therefore, there is always a need to develop animproved glove so as to meet the requirement of environmentalprotection.

Although a glove made of natural rubber is known to beenvironmentally-friendly, the mechanical properties such as Young'smodulus of the natural rubber glove are unsatisfactory. In addition, thenatural rubber is disadvantageous to be a source of irritation such asskin itch, asthma and shock, etc.

JP 9-505612 (1997) described a glove manufactured by nitrile-butadienerubber (NBR) latex. Although the NBR glove contains no known sources ofirritation and has good resistance to chemical solvents, the commercialapplications thereof are limited due to high manufacturing costs.

JP 55-163202 (1980) described a process for manufacturing a glove byusing styrene-butadiene rubber (SBR). The SBR material iscost-effective. However, such glove has poor tensile stress and low tearstrength, and the immersion molding effects of such glove areunsatisfactory.

JP 7-506642 (1995) described a process for manufacturing a glove byusing thermoplastic butadiene-styrene-butadiene block polymers. Theircommercial applications are limited due to the poor flexibility of suchmaterials and complex processes for producing the gloves therefrom.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a cost-effectiveprocess for producing a glove from an elastomeric composition, which hasan interpenetrating network structure.

In accordance with a first aspect of the present invention, there isprovided a process for producing a glove having an interpenetratingnetwork structure. Firstly, a mold is contacted with an elastomericcomposition comprising a base latex and a thermoplasticethylene-vinylacetate (EVA) copolymer latex, wherein the base latexcomprises a styrene-butadiene rubber (SBR) latex and a carboxylatedstyrene-butadiene rubber (C-SBR) latex, and the mixing ratio of the baselatex to the EVA copolymer latex is from 95:5 to 40:60. Then, theelastomeric composition on the mold is allowed to perform avulcanization reaction, thereby forming the elastomeric article havingthe interpenetrating network structure.

In an embodiment, the process further comprises a step of immersing themold into a solution of a coagulant selected from a group consisting ofcalcium nitrate, calcium chloride, alky ammonium and a combinationthereof, before the step of contacting the mold with the elastomericcomposition.

In an embodiment, the process further comprises a step ofsurface-treating the mold after the step of contacting the mold with theelastomeric composition and before the vulcanization reaction isperformed.

In an embodiment, the step of surface-treating the mold is performed byusing a surface-treating agent comprising 10˜20% by weight of asynthesized resin, 10˜20% by weight of an acrylic-styrene resin, 1˜10%by weight of a silicon resin and the balance of water.

Preferably, the base latex comprises from 1% to 40% by mole ofcarboxylate group.

Preferably, the base latex comprises from 5% to 20 % by mole ofcarboxylate group.

In an embodiment, the elastomeric composition further comprises at leastone additive selected from a group consisting of activators,vulcanization agents, vulcanization accelerators, anti-aging agents,enforcement agents, fillers and additional latices.

Preferably, the activator includes zinc oxides, in amount of from 1% to10% by weight based on the total weight of the base latex and the EVAcopolymer latex.

Preferably, the vulcanization agent includes sulfur, organic sulfide anda combination thereof, in amount of from 0.1% to 2% by weight based onthe total weight of the base latex and the EVA copolymer latex.

Preferably, the vulcanization agent includes at least one selected froma group consisting of zinc N-ethyl-N-phenyldithiocarbamate, zincdimethyldithiocarbamate, zinc diethyldithiocarbamate, zincdibutyldithiocarbamate, zinc mercaptobenzothiazole, tetramethyldisulfide and a combination thereof, in amount of from 0.5% to 10% byweight based on the total weight of the base latex and the EVA copolymerlatex.

Preferably, the anti-aging agent includes phenolic compounds or aminecompounds, in amount of from 0.5% to 3% by weight based on the totalweight of the base latex and the EVA copolymer latex.

Preferably, the enforcement agent includes at least one selected from agroup consisting of nano-scale montmorillonite, mica, clay, bentonite,saponite, silica, titanium dioxide, potassium titanate whisker and acombination thereof, in amount of less than 20% by weight based on thetotal weight of the base latex and the EVA copolymer latex.

Preferably, the additive includes at least one selected from a groupconsisting of photocatalyst, talcum powder, calcium carbonate, titaniumdioxide, antistatic agent, far infrared-ray emitting agent, pigment anda combination thereof, in amount of less than 20% by weight based on thetotal weight of the base latex and the EVA copolymer latex.

Preferably, the additional latices include aqueous polyurethane, aqueousnitrile rubber latex, acrylic resin latex and a combination thereof, inamount of less than 50% by weight based on the total weight of the baselatex and the EVA copolymer latex.

In accordance with a second aspect of the present invention, there isprovided a process for producing a glove having an interpenetratingnetwork structure. Firstly, a mold is contacted with an elastomericcomposition. The elastomeric composition includes a latex mixturecomprising a base latex and a thermoplastic ethylene-vinylacetate (EVA)copolymer latex, wherein the base latex comprises a styrene-butadienerubber (SBR) latex and a carboxylated styrene-butadiene rubber (C-SBR)latex, 1˜10 weight parts of an activator; 0.1˜2 weight parts of avulcanization agent; and 0.5˜10 weight parts of a vulcanizationaccelerator. Then, the elastomeric composition on the mold is allowed toperform a vulcanization reaction, thereby forming the glove articlehaving the interpenetrating network structure.

In an embodiment, the composition further comprises 0.5˜3 weight partsof an anti-aging agent, optionally an enforcement agent less than 20weight parts, optionally a filler less than 20 weight parts andoptionally additional latices less than 50 weight parts.

The above objects and advantages of the present invention will becomemore readily apparent to those ordinarily skilled in the art afterreviewing the following detailed description.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The objects of meeting the requirements of environmental protection andcost-effectiveness can be achieved by a method of the present inventionfor producing an elastomeric article having an interpenetrating networkstructure.

The elastomeric composition of the present invention comprises a baselatex and a thermoplastic ethylene-vinylacetate (EVA) copolymer latex.The base latex comprises at least one of a styrene-butadiene rubber(SBR) latex and a carboxylated styrene-butadiene rubber (C-SBR) latex.Some suitable additives, for example activators, vulcanization agents,vulcanization accelerators, anti-aging agents, enforcement agents,fillers and additional latices, can be combined into the elastomericcomposition so as to impart desirable properties of the producedelastomeric articles. During a vulcanization process, the base latex andthe EVA copolymer latex of the elastomeric composition are cross-linkedto form the interpenetrating network structure of the elastomericarticle having the interpenetrating network structure so as to impartexcellent elastomeric properties such as elasticity and extensibility,as will be described hereinafter. More specifically, due to theexcellent elasticity and extensibility, the elastomeric article producedfrom the elastomeric composition will generate different contractibledegrees for the moving and motionless portions of the wearer. Thus, thewearer can feel the elastomeric article next to the skin.

The carboxylated styrene-butadiene rubber (C-SBR) latex is obtained byintroducing carboxylate groups into the molecule chains of SBR. The baselatex comprises preferably from 1% to 40%, and more preferably from 5%to 20 % by mole of carboxylate groups. The presence of the C-SBR latexcan provide good immersion molding effects of the produced elastomericarticle and increase hydrogen-bond density of the SBR latex. The tensilestress and tear strength of the elastomeric article can be enhancedaccordingly. The hydrogen bonding of C-SBR and/or SBR latex and EVAcopolymer latex is increased during vulcanization so as to promoteformation of the interpenetrating network structure. Furthermore, theEVA copolymer latex can also increase immersion molding effects of theproduced elastomeric article, and thus provides good softness and touchfeel.

The above-mentioned base latex can be used alone or in a mixture of atleast two C-SBR lattices with different carboxylate groups. In addition,the combination of the SBR latex and the C-SBR latex can be used. Themixing ratio of the base latex to the EVA copolymer latex is preferablyfrom 99:1 to 5:95, and more preferably from 95:5 to 40:60.

The activator used in the present invention may be zinc oxides, inamount of from 1% to 10% by weight based on the total weight of the baselatex and the EVA copolymer latex.

The vulcanization agent includes for example sulfur, organic sulfide anda combination thereof, in amount of from 0.1% to 2% by weight based onthe total weight of the base latex and the EVA copolymer latex.

The vulcanization agent is used to promote vulcanization reaction andcan include for example zinc N-ethyl-N-phenyldithio-carbamate (PX), zincdimethyldithiocarbamate (PZ), zinc diethyldithiocarbamate (EZ), zincdibutyldithiocarbamate (BZ), zinc mercaptobenzothiazole (MZ),tetramethyl disulfide and a combination thereof, in amount of from 0.5%to 10% by weight based on the total weight of the base latex and the EVAcopolymer latex.

The anti-aging agent may be phenolic compounds or amine compounds, inamount of from 0.5% to 3% by weight based on the total weight of thebase latex and the EVA copolymer latex.

The enforcement agent used in the present invention includes for examplenano-scale montmorillonite, mica, clay, bentonite, saponite, silica,titanium dioxide, potassium titanate whisker and a combination thereof,in amount of less than 20% by weight based on the total weight of thebase latex and the EVA copolymer latex.

The additive used in the present invention includes for examplephotocatalyst, talcum powder, calcium carbonate, titanium dioxide,antistatic agent, far infrared-ray emitting agent, pigment and acombination thereof, in amount of less than 20% by weight based on thetotal weight of the base latex and the EVA copolymer latex.

The additional latices can include for example aqueous polyurethane,aqueous nitrile rubber (NBR) latex, acrylic resin latex and acombination thereof, in amount of less than 50% by weight based on thetotal weight of the base latex and the EVA copolymer latex.

The additives described hereinbefore can be incorporated into theelastomeric composition of the present invention in combination with adispersing agent so as to increase dispersing effect thereof. Dependingon the types of additives, such dispersing agents can be any suitablesurfactant in amount of from 0.3% to 1% by weight based on the weight ofthe additive to be used.

A process for producing a glove will be described as follows. Firstly, aglove mold is immersed in a solution of a coagulant comprising calciumnitrate, calcium chloride, alky ammonium or a combination thereof. Afterthe coagulant is precipitated from the solution, the glove mold isremoved and dried. Then, the glove mold is immersed in an elastomericcomposition of the present invention, removed and dried. Optionally, theglove mold is surface-treated by using a surface-treating agentcomprising 10˜20% by weight of a synthesized resin, 10˜20% by weight ofan acrylic-styrene resin, 1˜10% by weight of a silicon resin and thebalance of water. Then, the elastomeric composition on thesurface-treated glove mold is vulcanized at a temperature between 90 and180° C. for several minutes to several hundred minutes. After thevulcanized elastomeric composition is cooled and demolded, a glovehaving an interpenetrating network structure is formed.

The present invention will be further understood in more details withreference to the following examples.

EXAMPLE Examples 1˜4 Preparation of Elastomeric Composition

Four elastomeric compositions are prepared by the components indicatedin Table 1 below, each component being represented by weight parts.TABLE 1 Example# Component 1 2 3 4 SBR 100 0 40 50 C-SBR* 0 100 60 50EVA 20 10 12 15 Sulfur 0.6 0.6 0.6 0.6 Zinc oxide 2 2 2 2 PX** 2 2 2 2nano-scale clay 6 6 6 6 aqueous nitrile rubber 10 10 10 10 latex water20 20 20 20*comprising 10% by mole of carboxylate group**zinc N-ethyl-N-phenyldithiocarbamate

Preparation of Glove

Four sets of glove molds are immersed in an aqueous solution containing0.5˜35% by weight of calcium nitrate. After calcium nitrate isprecipitated from the solution, the glove mold is removed and dried.Then, the four sets of glove molds are immersed in the elastomericcompositions of the examples 1˜4, respectively. Then, these glove moldsare removed and dried. Optionally, the glove mold is surface-treated byusing a surface-treating agent comprising 15% by weight of a synthesizedresin, 15% by weight of an acrylic-styrene resin, 4% by weight of asilicon resin and 66% by weight of water. Then, the elastomericcomposition on the surface-treated glove mold is vulcanized at atemperature of 150° C. for 15 minutes. After the vulcanized elastomericcompositions are cooled and demolded, gloves having interpenetratingnetwork structures are formed.

Testing of Physical Properties

Table 2 shows the test results of physical properties of the glovesproduced in the examples 1˜4. TABLE 2 Example# Physical properties 1 2 34 Ultimate tensile stress (MPa) 20.3 23.3 21.9 20.5 Ultimate elongation(%) 560 740 680 620 Tensile stress @ 100% (MPa) 1.03 1.18 1.10 1.06Tensile stress @ 200% (MPa) 1.90 2.27 2.11 2.03 Tensile stress @ 300%(MPa) 2.87 3.38 3.22 3.12 Tensile stress @ 400% (MPa) 4.67 5.13 5.014.88 Tensile stress @ 500% (MPa) 5.77 7.70 7.12 6.99

The results of Table 2 show that the gloves produced by using theelastomeric compositions of the present invention have excellent tensilestress and elongation. Thus, good softness and touch feel can beprovided to the wearer.

Combustion Test of Glove

The combustion tests of the above gloves are performed to measureacidity of the combusted gases and contents of dioxin.

The results of the combustion tests show that the acidities of thecombusted gases have pH values between 4.0 and 4.6, and the dioxincontent is approximately 0 ng/g. In contrast, the acidities of thecombusted gases for a commercial PVC glove is about pH 2.0, and thedioxin content is about 25 ng/g.

The above results show the gloves produced by using the elastomericcompositions of the present invention have superior environmentalprotection effects.

While the invention has been described in terms of what is presentlyconsidered to be the most practical and preferred embodiments, it is tobe understood that the invention needs not be limited to the disclosedembodiment. On the contrary, it is intended to cover variousmodifications and similar arrangements included within the spirit andscope of the appended claims which are to be accorded with the broadestinterpretation so as to encompass all such modifications and similarstructures.

1. A process for producing a glove having an interpenetrating networkstructure, comprising steps of: contacting a mold with an elastomericcomposition comprising a base latex and a thermoplasticethylene-vinylacetate (EVA) copolymer latex, said base latex comprisinga styrene-butadiene rubber (SBR) latex and a carboxylatedstyrene-butadiene rubber (C-SBR) latex and the mixing ratio of said baselatex to said EVA copolymer latex being from 95:5 to 40:60; and allowingsaid elastomeric composition on said mold to perform a vulcanizationreaction, thereby forming said elastomeric article having saidinterpenetrating network structure.
 2. The process according to claim 1wherein said base latex comprises from 1% to 40% by mole of carboxylategroup.
 3. The process according to claim 2 wherein said base latexcomprises from 5% to 20 % by mole of carboxylate group.
 4. The processaccording to claim 1 wherein said elastomeric composition comprises atleast one additive selected from a group consisting of activators,vulcanization agents, vulcanization accelerators, anti-aging agents,enforcement agents, fillers and additional latices.
 5. The processaccording to claim 4 wherein said activator includes zinc oxides, inamount of from 1% to 10% by weight based on the total weight of saidbase latex and said EVA copolymer latex.
 6. The process according toclaim 4 wherein said vulcanization agent includes sulfur, organicsulfide and a combination thereof, in amount of from 0.1% to 2% byweight based on the total weight of said base latex and said EVAcopolymer latex.
 7. The process according to claim 4 wherein saidvulcanization agent includes at least one selected from a groupconsisting of zinc N-ethyl-N-phenyldithiocarbamate, zincdimethyldithiocarbamate, zinc diethyldithiocarbamate, zincdibutyldithiocarbamate, zinc mercaptobenzothiazole, tetramethyldisulfide and a combination thereof, in amount of from 0.5% to 10% byweight based on the total weight of said base latex and said EVAcopolymer latex.
 8. The process according to claim 4 wherein saidanti-aging agent includes phenolic compounds or amine compounds, inamount of from 0.5% to 3% by weight based on the total weight of saidbase latex and said EVA copolymer latex.
 9. The process according toclaim 4 wherein said enforcement agent is a nano-scale enforcement agentincluding at least one selected from a group consisting ofmontmorillonite, mica, clay, bentonite, saponite, silica, titaniumdioxide, potassium titanate whisker and a combination thereof, in amountof less than 20% by weight based on the total weight of said base latexand said EVA copolymer latex.
 10. The process according to claim 4wherein said additive includes at least one selected from a groupconsisting of photocatalyst, talcum powder, calcium carbonate, titaniumdioxide, antistatic agent, far infrared-ray emitting agent, pigment anda combination thereof, in amount of less than 20% by weight based on thetotal weight of said base latex and said EVA copolymer latex.
 11. Theprocess according to claim 4 wherein said additional latices includeaqueous polyurethane, aqueous nitrile rubber latex, acrylic resin latexand a combination thereof, in amount of less than 50% by weight based onthe total weight of said base latex and said EVA copolymer latex. 12.The process according to claim 1 further comprising a step of immersingsaid mold into a solution of a coagulant selected from a groupconsisting of calcium nitrate, calcium chloride, alky ammonium and acombination thereof, before said step of contacting said mold with saidelastomeric composition.
 13. The process according to claim 1 furthercomprising a step of surface-treating said mold after said step ofcontacting said mold with said elastomeric composition and before saidvulcanization reaction is performed.
 14. The process according to claim13 wherein said step of surface-treating said mold is performed by usinga surface-treating agent comprising 10˜20% by weight of a synthesizedresin, 10˜20% by weight of an acrylic-styrene resin, 1˜10% by weight ofa silicon resin and the balance of water.
 15. A process for producing aglove having an interpenetrating network structure, comprising steps of:contacting a mold with an elastomeric composition, wherein saidelastomeric composition comprises: 100 weight parts of a latex mixturecomprising a base latex and a thermoplastic ethylene-vinylacetate (EVA)copolymer latex, said base latex comprising a styrene-butadiene rubber(SBR) latex and a carboxylated styrene-butadiene rubber (C-SBR) latexand the mixing ratio of said base latex to said EVA copolymer latexbeing from 99:1 to 5:95; 1˜10 weight parts of an activator, based on thetotal weight of said latex mixture; 0.1˜2 weight parts of avulcanization agent, based on the total weight of said latex mixture;and 0.5˜10 weight parts of a vulcanization accelerator, based on thetotal weight of said latex mixture; and allowing said elastomericcomposition on said mold to perform a vulcanization reaction, therebyforming said glove having said interpenetrating network structure. 16.The process according to claim 15 wherein said elastomeric compositionfurther comprises: 0.5˜3 weight parts of an anti-aging agent, based onthe total weight of said latex mixture; optionally an enforcement agentless than 20 weight parts based on the total weight of said latexmixture; optionally a filler less than 20 weight parts based on thetotal weight of said latex mixture; and optionally additional laticesless than 50 weight parts based on the total weight of said latexmixture.